Independent Rotating Transfer Sectors for E-Cig Welding Throughput

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Solution Overview

Problem

The production of electronic cigarettes faces challenges in maintaining high throughput due to the long times required for welding operations, particularly in automated machines where components need to be stopped for welding, complicating the integration of efficient welding processes.

Innovation Solution

A welding station and method that utilize independent, rotatable transfer sectors to accelerate parts from a feeding area to a welding area, reducing the total time components spend in the welding station by compensating for technical welding times through increased transfer speeds, allowing for efficient integration with other operations in automatic machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If welding operations are performed in automated machines, then manufacturing precision and automation are improved, but productivity decreases due to long welding times requiring component stoppage

Engineering Contradiction:

Improveautomation of welding operationsVSAvoidthroughput of welding operations

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The transfer device is divided into multiple independent transfer sectors (first transfer sector, second transfer sector, etc.), each capable of independently receiving and transferring parts. This segmentation allows different sectors to operate at different stages of the welding cycle simultaneously, enabling continuous throughput while maintaining precise welding operations in dedicated welding areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The transfer sectors are designed to rotate at variable speeds, allowing acceleration during transfer operations and deceleration or stopping during welding operations. This dynamic speed control enables the system to maintain high overall throughput while accommodating the stationary nature of welding processes, resolving the contradiction between automation and productivity.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If components are stopped for welding operations, then welding precision and quality are improved, but loss of time increases due to interruption of continuous production flow

Engineering Contradiction:

Improvewelding qualityVSAvoidtotal time in welding station

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

While one transfer sector is stopped to allow welding operations to complete with high precision, other transfer sectors continue to receive new parts from the feeding area and transfer them to welding areas. This creates a continuous flow of useful actions across the system, minimizing overall loss of time while maintaining welding quality through controlled stopping at critical moments.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Parts are pre-positioned in the feeding area and transfer sectors are pre-loaded with components before welding begins. This preliminary preparation allows the system to maintain continuous operation with minimal interruption, as subsequent welding operations can proceed without waiting for part preparation or loading.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If multiple welding stations are used to maintain throughput, then productivity is improved, but device complexity increases due to integration of multiple stations

Engineering Contradiction:

Improvethroughput of welding operationsVSAvoidnumber of welding stations

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each transfer sector serves multiple functions: receiving parts from the feeding area, transporting them to welding areas, and delivering welded parts to the output area. The same physical structure performs what would traditionally require separate dedicated stations, reducing overall device complexity while maintaining high productivity through coordinated multi-sector operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11576439B2Station and method for welding parts of electronic cigarettes

Publication Date: 2023.02.14 GD SPA

AI summary

A welding station for welding parts of electronic cigarettes includes feeding means, set in a feeding area for feeding parts of electronic cigarettes to be welded; welding means, set in a welding area, downstream of the feeding area, for welding the parts of electronic cigarettes; and a transfer device, set between the feeding means and the welding means for receiving from the feeding means the parts of electronic cigarettes to be welded and transferring them from the feeding area to the welding area. The transfer device includes a first transfer sector and a second transfer sector, pre-arranged for receiving from the feeding means, respectively, first parts and second parts of electronic cigarettes to be welded and transferring them into the welding area. The first transfer sector and the second transfer sector are mobile in rotation about an axis, independently of one another.